Vegetable-based compositions and articles, and methods of making same

ABSTRACT

Disclosed is a shaped article of manufacture formed from a vegetable-based composition comprising a combination of vegetable-based compound(s) and insect wax wherein the combination of ingredients provides enhanced release properties and unique and desirable aesthetic characteristics.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. application Ser. No.09/905,686, filed Jan. 9, 2001, which application in turn claimspriority to U.S. Provisional Application No. 60/245,073 filed Nov. 2,2000, the disclosures of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to vegetable-based compositions, articlesof manufacture containing these compositions and to methods ofmanufacturing such articles. According to preferred aspects of theinvention, the article is a candle with desirable aesthetic propertiesand/or improved mold-release properties.

BACKGROUND OF THE INVENTION

Vegetable waxes have been used for centuries to make articles ofmanufacture, particularly candles. Although the use of candles hasobviously been supplanted as a primary source of light in most cultures,candles are nevertheless used for a large number of diverse reasons,including to enhance the decoration, atmosphere and mood of thelocations in which they are used. Accordingly, while it remainsnecessary that candles be manufactured from materials and in a mannerthat ensures that will burn in pleasing way (e.g., without excessivesmoke or soot), there has been an increasing desire to obtain candleswith pleasing visual features.

For example, it has been reported in U.S. Pat. No. 5,762,487—Kujawski(which is incorporated herein by reference) that many varied andrelatively complex techniques have been used to produce candles withinteresting decorative effects. For example, the Kujawski patentdescribes candles made by a casting method in which the mold is filledwith discrete layers of wax of different colors and then tilted toproduce angled stripes of different colors. This patent also disclosescandle making techniques which involve creating a random mosaic effectby adding solid wax chips of various colors to the mold and then fillingwith a molten wax. Other complex decorative techniques are alsodisclosed, such as aerating the wax before or after it is poured intothe mold and adding pieces of ice to the wax to create a honeycombeffect.

While the above techniques may have been successful in creatinginteresting decorative effects, they are all relatively complex, timeconsuming and/or labor intensive procedures which ultimately add cost tothe finished product. Furthermore, certain of the materials which haveheretofore been used to manufacture candles have become increasinglydisfavored in recent years. For example, the Kujawski patent disclosesthat the candles are preferably formed from petroleum based waxes (i.e.,paraffin waxes). However, petroleum products have become increasinglyexpensive and are a further concern because they represent annon-renewable resource. As a result it has become increasingly desirableto produce “green” candles, that is, candles which do not containpetroleum derived products. Furthermore, although Kujawski disclosesthat beeswax may be used as alternative to petroleum-based waxes, theformation of candles exclusively from beeswax is generally disfavoredfrom a cost perspective due to the relatively high cost of beeswax.

U.S. Pat. No. 6,063,144—Calzada, which is incorporated herein byreference, discloses a candle formed from non-parafin materialsconsisting essentially of at least 30 parts by weight of stearic acid,at least 5 parts by weight of vegetable-derived wax with a melting pointof at least 50 C, vegetable oil, fragrance and an oxidation inhibitor.The Calzada patent does not disclose that the article formed from such acomposition has advantageous aesthetic qualities or decorative effects.

In view of these and other potential deficiencies in the techniques andmaterials heretofore used to produce candles and other articles, thepresent inventor has developed articles which can be efficientlymanufactured while at the same time possessing unique and highlyattractive decorative effects.

BRIEF DESCRIPTION OF THE FIGURES

Attached as FIG. 1 is a series of photographs showing candles made inaccordance with one embodiment of the present invention.

Attached as FIG. 2 is a series of photographs showing candles made inaccordance with a second embodiment of the present invention

Attached as FIG. 3 is a series of photographs showing candles made inaccordance with a third embodiment of the present invention.

Attached as FIG. 4 is a series of photographs showing candles made inaccordance with a fourth embodiment of the present invention.

Attached as FIG. 5 is a series of photographs showing candles made inaccordance with a fourth embodiment of the present invention.

Attached as FIG. 6 is a photograph which shows a candles which does notachieve the preferred decorative effects of the present invention.

Attached as FIG. 7 is a photograph which shows candles made inaccordance with the present invention in a variety of colors, shapes andsizes.

DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS

The Compositions and the Articles

The present inventor has discovered that desirable articles ofmanufacture can be obtained by the use of compositions comprising, on arelative basis, from about 80 parts to about 99 parts by weight ofvegetable-derived compound(s) and from about 1 part to about 20 parts byweight of insect wax. According to preferred embodiments, the article isa molded candle which exhibits one or more of a variety of decorativeeffects, as described in more detail hereinafter. According to highlypreferred embodiments, the candle body of the present invention consistsessentially of vegetable-derived compound(s) and insect wax.

The term “vegetable-derived compound(s)” as used herein refers to anysingle compound or combination of compounds which are of the typecommonly derived from vegetable or fruit sources. Although it iscontemplated that any vegetable-derived compound(s) may be adapted forused in accordance with the present invention, it is generally preferredthat the vegetable-derived compound(s) comprise, and even morepreferably are selected from the group consisting essentially ofvegetable waxes, vegetable acids and combinations of acids and waxes ofthe type derived from vegetable and fruit sources. The term “consistingessentially of” is used herein in its art-recognized sense to expressthat the composition is open to the inclusion of additional ingredientsin amounts which do not adversely affect its novel and basic properties.

For embodiments which incorporate vegetable acids, it is generallypreferred that the vegetable acid comprise, and preferably consistessentially of, stearic acid. As used herein, the term “stearic acid”includes any of the commercial grades of stearic acid. While academicauthorities and textbooks treat “stearic acid” as a synonym for the purechemical compound octadecanoic acid (C₁₇H₃₅COOH), commercial practice,which is the intended meaning herein, is broader and uses the same termfor mixtures comprising major amounts of one or more of bothoctadecanoic acid, the 16 carbon hexadecanoic acid or palmitic acid(C₁₅H₃₁COOH), together with minor amounts of lower and higher homologs,the corresponding monounsaturated acids 9-Octadecanoic acid (oleic acid,C₁₇H₃₃COOH) and 9-Hexadecanoic acid (palmitoleic acid, C₁₅H₂₉COOH) and avariety of trace impurities characteristic of the source of the rawmaterial and the method used in its refining. Furthermore, it will beappreciated that while the stearic acid used in accordance with thepresent invention is preferably obtained by the processing of vegetablematerials, it will be appreciated that stearic acid compounds may bederived form other sources and are considered within the scope the term“vegetable-derived compound(s)” as used herein.

According to certain preferred embodiments, the vegetable acid of thepresent invention comprises one or more compounds corresponding to theformula C_(x)H_(y)COOH, where x is from about 15 to about 17 and y isfrom about 29 to about 35.

Likewise, while the vegetable waxes used in accordance with the presentinvention are preferably obtained by the processing of vegetablematerials, it will be appreciated that such wax compounds may be derivedform other sources and are considered within the scope the term“vegetable-derived compound” as used herein. In other words, it isconsidered that synthetic forms of, or substitutes for, the vegetablewaxes and vegetable acids are within the meaning of those terms as usedherein.

Commercially available stearic acid is sold by Procter & GambleChemicals under the trade designation V-1855 and is preferably used asthe vegetable acid component of the present compositions.

Commercially available palmitic acid is sold by Procter & GambleChemicals under the trade designations V-1695 and V-1655 and ispreferably used as a vegetable acid component in certain embodiments ofthe present compositions.

With respect to the vegetable wax compounds, particularly preferredcompounds are palm-derived waxes, candelilla waxes, cork fiber waxes,hemp fiber waxes, sugar cane waxes, bayberry waxes, Japan waxes, bambooleaf waxes, rice waxes, esparto wax, and mixtures and combinations ofthese. In general, palm-derived waxes are preferred and include carnaubawax, ouricury, caranda and raffia. As is known, palm derived waxesgenerally contain high concentrations, for example, from about 80% toabout 90% of alkyl esters of higher fatty acids. Such esters may includeesters of palmitic acids, stearic, oleic acids and combinations of twoor more of those.

In general, the vegetable wax of the present invention preferably iscomprised in major proportion of palmitic ester waxes, and even morepreferably the vegetable wax comprises at least about 70% by weight ofesters derived from palmitic, stearic or oleic acids, with at leastabout 80% by weight of such esters being even more preferred. Accordingto highly preferred embodiments, the vegetable wax component of thepresent compositions comprises, and preferably consist essentially of,lower alkyl (C₁-C₄) esters, and even more preferably methyl esters, ofstearic acids. Among the preferred methyl esters of stearic acid aremethyl ester of hexadecanoic acid and methyl ester of octadecanoic acid.A combination of methyl ester of hexadecanoic acid and methyl ester ofoctadecanoic acid is sold by Procter & Gamble Chemicals under the tradedesignation CD-1618H and is preferably used as the vegetable waxcomponent of the present composition.

The vegetable-derived compound(s) preferably comprise a majorproportion, on a relative weight basis, of stearic acid and minorproportion of esters of stearic acid. Preferably the vegetable-derivedcompound(s) comprise, on a relative basis, from about 70 to about 90parts by weight of stearic acid and from about 10 parts by weight toabout 30 parts by weight of esters of stearic acid.

The present inventor has found that compositions comprising a majorproportion of vegetable-derived compound(s) and from about 1% by weight,and even more preferably from about 2% by weight, up to about 20% byweight of insect wax (based on the combined weight of vegetable-derivedcompound(s) and insect wax) is capable of producing unique and highlydesirable aesthetic properties. More particularly, the compositions,when formed into shaped articles, and particularly candles, exhibit avariety of surface appearances which flow from the combinationsdescribed herein without the need for any additional or complexdecorating procedures. Applicant has found that the desirable aestheticeffect is generally not achieved at insect wax concentrations belowabout 1% or at about 20% or above.

Furthermore, as explained in connection with the method aspects hereof,amounts of beeswax below about 1% do not provide certain processingadvantages that are obtained when concentrations within the describedrange are used. In addition, applicant has found and believes that theadvantageous aesthetic features of the present invention are notachieved with compositions which eliminate the vegetable-basedcompound(s) and utilize instead petroleum-derived compounds of the typeswhich have heretofore used in the manufacture of candles.

The term “insect wax” as used herein refers not only to waxes producedby naturally occurring insects, but also any waxes produced bygenetically altered insects and to waxes produced synthetically asinsect wax substitutes. Synthetic substitutes for insect wax aredisclosed in U.S. Pat. Nos. 4,500,359, 4,292,008 and 4,151,00, each ofwhich is incorporated herein by reference.

The preferred insect wax in accordance with the present invention isbeeswax. In general, based on various publications, beeswax contains of10.5-14% hydrocarbons, 71-72% alkyl esters of monocarboxylic acids,0.6-0.8% choloesteryl esters, 12%-14.5% free acids, 1-1.5% freealcohols, and other ingredients, including coloring matter, lactone,moisture and mineral impurities. See Van Nostrand Reinhold Encyclopediaof Chemistry (4^(th) Edition); Beeswax-Composition and Analysis, byTulloch, National Research Council of Canada; and U.S. Pat. No.4,151,001, each one of which is incorporated herein by reference.

In general, the simple esters of beeswax are comprised in majorproportion of palmitate compounds, including myricyl palmitate.

The reason that the combination of vegetable-derived compound(s) andinsect waxes in accordance with the present invention produces articleswith the aesthetic effects discovered by the applicant is not fullyunderstood.

With reference now to FIG. 1, color photographs of two cylindricallyshaped articles in accordance with the present invention are shown.These articles each exhibit a visual effect which is described herein asa thumb-print pattern. This pattern is achieved with insect wax inamounts of from about 2% to about 6% of the composition. The articles inFIG. 1 contain about 2% and 3%, respectively from left to right, ofbeeswax with the remainder being vegetable-derived compound(s)comprising about 80 parts by weight of V-1855 and 20 parts by weight ofCD-1618H.

With reference now to FIG. 2, color photographs of three cylindricallyshaped articles in accordance with the present invention are shown.These articles each exhibit a visual effect which is described herein ascellular or tortoise shell pattern. It should be noted that thesearticles include a thumb-print pattern within each cell of the tortoiseshell pattern. This combination of patterns is highly preferred, and isgenerally achieved only with compositions that contain insect wax, andpreferably beeswax, in amounts of from about 4% to about 6% of the waxcomponent of the composition. The articles in FIG. 2 contain about 4%,5% and 6%, respectively from left to right, of beeswax with theremainder being vegetable-derived compound(s) comprising about 80 partsby weight of V-1855 and 20 parts by weight of CD-1618H.

With reference now to FIG. 3, color photographs of four cylindricallyshaped articles in accordance with the present invention are shown.These articles each contain tortoise shell pattern. However, each cellor bordered segment which is part of the overall tortoise shell patternis made from or contains what is referred to herein as a sunburstpattern. This combination of patterns is preferred in certainembodiments, and is generally achieved only with compositions thatcontain insect wax, and preferably beeswax, in amounts of from about 7%to about 10% of the wax component of the composition. The articles inFIG. 3 contain about 7%, 8%, 9% and 10%, respectively from left toright, of beeswax with the remainder being vegetable-derived compoundscomprising about 80 parts by weight of V-1855 and 20 parts by weight ofCD-1618H.

With reference now to FIG. 4, color photographs of two cylindricallyshaped articles in accordance with the present invention are shown.These articles each exhibit a visual effect which is described herein asmarble pattern. It should be noted that these articles generally do notcontain either a thumb-print pattern or a sunburst pattern effect. Themarble pattern is generally achieved only with compositions that containinsect wax, and preferably beeswax, in amounts of from about 11% toabout 12% of the wax component of the composition. The articles in FIG.4 contain about 11% and 12 6%, respectively from left to right, ofbeeswax with the remainder being vegetable-derived compounds comprisingabout 80 parts by weight of V-1855 and 20 parts by weight of CD-1618H.

With reference now to FIG. 5, color photographs of three cylindricallyshaped articles in accordance with the present invention are shown.These articles each exhibit a visual effect which is described herein asspotted or mottled pattern. It should be noted that ceratin of these,particularly the article in picture on the left side of the figure, alsoinclude elements of the marble pattern. The spotted patterns isgenerally achieved only with compositions that contain insect wax, andpreferably beeswax, in amounts of from about 13% to about 15% of the waxcomponent of the composition. The articles in FIG. 5 contain about 13%,14% and 15%, respectively from left to right, of beeswax with theremainder being vegetable-derived compounds comprising about 80 parts byweight of V-1855 and 20 parts by weight of CD-1618H.

With reference now to FIG. 6, a color photograph of a cylindricallyshaped articles that does not exhibit the preferred pattern effect ofthe present invention is shown. The article in FIG. 6 contains about 20%of beeswax and 80% by weight of being vegetable-derived compoundscomprising about 80 parts by weight of V-1855 and 20 parts by weight ofCD-1618H.

The compositions of the present invention, and the articles from whichthey are made, therefore preferably comprise, and even more preferablyconsist essentially of, from about 70 parts by weight to about 98 partsby weight of vegetable-derived compound(s), and insect wax (preferablybeeswax) in an amount of from about 2 parts by weight to about 15 partsby weight, more preferably in amounts of from about 4 parts to about 15parts by weight, and even more preferably in amounts of from about 4parts to about 12 parts by weight. It will be appreciated, of coursethat other components, such as perfumes, fillers, dyes, etc. may beincluded in the compositions and articles hereof without detriment.

Furthermore, it will be appreciated that the present articles can beformed from material other than the present composition, provided thepresent composition is utilized to provide at least one visual surfaceportion of the article. This could be achieved, for example, by coatingor layering the present composition onto a support structure formed fromother components. However, it is preferred in many embodiments, such ascandles for example, that the article be formed in substantial portionfrom the present compositions. Such articles will receive the benefit ofachieving a through-pattern feature for the article, that is, thedecorative effect will exist throughout the article, and not just on alocalized surface or area thereof. As a result, the effect will remainvisible from all angles even as the candle burns.

The Methods

It is contemplated that many methods may adapted to form the presentcompositions into articles, and articles made by all such methods arewithin the scope hereof. However, the present compositions exhibitadditional advantage when used as the material for molding or castingtechniques. More particularly, such techniques utilize a mold whichdefines a cavity having the desired geometry of the article beingproduced. The present composition, preferably in molten form, isintroduced into the mold, preferably by pouring, to fill the cavity andthereby taken on the desired shape. In the case of candle making, theprocess also generally includes placing a wick into the cavity of themold, for example by suspending the wick from a cross-bar over the mouthof the mold, and then placing the molten wax into the mold and aroundthe wick. The wax is then allowed to solidify, and once the wax has set,the candle is removed from the mold.

Applicants have noted a significant processing advantage associated withthe compositions of the present invention when used to make articles bythe molding process. More particularly, applicants have noted that theeasy with which the article is removed from one-piece molds is greatlyenhanced by the incorporation of insect wax into the presentcompositions. Although applicant does not intend to necessarily bound byits theory of operation, it is believed that vegetable-derivedcompounds, and particularly the preferred vegetable acids and waxes,undergo no substantial shrinkage upon solidification and setting in themold. As a result, it can sometimes be difficult to remove the shapedarticle from a one piece mold. Applicant has found that the addition ofas little as 1%, but preferably at least about 3%, by weight of insectwax to the composition produces just enough shrinkage of the article,without materially effecting the overall shape or integrity of thearticle, to greatly enhance the ease with which the article can beremoved from the mold. Of course, to further facilitate removal of thearticle from the mold, release agents can be applied to the insidesurfaces of the mold or introduced into the composition. Furthermore,numerous materials can be used to form the mold, such as glass, metal(including aluminum), plaster, or even cardboard.

The following examples are illustrative of the compositions, articlesand process of the present invention and should not be considered aslimiting the scope of the invention in any way.

EXAMPLE 1

Each of the following compositions was made from a vegetable-derivedcompound comprising about 80 weight percent of V-1855 and 20 weightpercent CD-1618H. A series of compositions were made comprising thisvegetable compound and beeswax comprising the balance of the compositionin amounts of 0, 1, 2, etc. to 20 percent by weight, hereinafterreferred to as Compositions 0 through 20.

Each composition was melted, blended thoroughly to produce asubstantially homogeneous mixture, poured at 140° F. into 1.875-inchaluminum candle molds, and allowed to harden at room temperatureovernight. Composition 0, containing no beeswax, was difficult to removefrom the mold. Composition 1, with 1 percent beeswax, shrank slightlyfrom the mold and released more easily than Composition 0. Composition2, with 2 percent beeswax, released easier than Sample Composition 1.Compositions 3 through 20 all shrank sufficiently from the mold torelease easily after solidification.

EXAMPLE 2

A candle wax compositions is made from a vegetable-derived compoundcomprising about 80 weight percent of palmitic acid (V-1695) and 20weight percent CD-1618H. A series of compositions are made comprisingthe vegetable derived compound, with the balance being quantities offrom 1 to about 20 percent by weight beeswax. These compositions aremelted, blended thoroughly to produce a substantially homogeneousmixture, poured at 140° F. into 1.875-inch aluminum candle molds, andallowed to harden at room temperature overnight. These compositions allshrink from the mold and release more easily than compositions withoutbeeswax.

EXAMPLE 3

A candle wax compositions is made from a vegetable-derived compoundcomprising about 50 weight percent of palmitic acid (V-1655) and 50weight percent V-1855. A series of compositions are made comprising thisvegetable derived compound, with the balance being quantities of from 1to about 20 percent by weight beeswax. These compositions are melted,blended thoroughly to produce a substantially homogeneous mixture,poured at 140° F. into 1.875-inch aluminum candle molds, and allowed toharden at room temperature overnight. These compositions all shrink fromthe mold and release more easily than compositions without beeswax.

1. A shaped article of manufacture comprising at least a surface layerformed of a composition comprising from about 80 parts by weight to lessthan about 99 parts by weight of vegetable-derived compound(s) and fromabout 1 part to about 20 parts by weight of insect wax, the combinationof said vegetable wax and said insect wax together providing saidsurface layer with an appearance selected from the group consisting of afingerprint pattern, a sunburst pattern, a marble pattern, a tortoisepattern, a spotted pattern and combinations of two or more of these. 2.The article of claim 1 wherein said vegetable-derived compound(s)comprise a mixture of vegetable wax and vegetable acid.
 3. The articleof claim 1 wherein said composition comprises from about 2% to about 15%by weight of insect wax.
 4. The article of claim 1 wherein saidcomposition comprises from about 4% to about 15% by weight of insectwax.
 5. The article of claim 1 wherein said composition comprises fromabout 4% to about 10% by weight of insect wax.
 6. The article of claim 1wherein said article consists of said composition.
 7. The article ofclaim 6 wherein said article is a candle.
 8. A shaped article ofmanufacture comprising at least a surface layer formed of avegetable-based composition, said composition comprising greater thanabout 80 parts by weight to less than about 98 parts by weight ofvegetable-based compound(s) and from about greater than about 2 parts byweight to less than about 20 parts by weight of insect wax.
 9. Theshaped article of claim 8 wherein said insect wax comprises beeswax. 10.The shaped article of claim 9 wherein said insect wax consistsessentially of beeswax.
 11. The article of claim 8 wherein saidvegetable-based compound(s) comprise a combination of vegetable acid andvegetable wax.
 12. The article of claim 11 wherein said vegetable acidcomprises stearic acid and said vegetable wax comprises ester of stearicacid.
 13. The article of claim 8 wherein said vegetable-basedcompound(s) comprise from about 70 parts by weight to about 90 parts byweight of stearic acid and from about 10 parts by weight to about 30parts by weight of ester of stearic acid.
 14. The article of claim 13wherein said vegetable-based compound(s) consist essentially of stearicacid and ester of stearic acid.
 15. The article of claim 13 wherein saidvegetable-based compound(s) comprise about 80 parts by weight of stearicacid and about 20 parts by weight of ester of stearic acid.
 16. Thearticle of claim 15 wherein said vegetable-based compound(s) compriseabout 80% by weight of stearic acid and about 20% by weight of ester ofstearic acid.
 17. A method of fabricating a molded article comprising:providing a composition comprising vegetable-derived compound(s) andinsect wax; molding said composition into a desired shape, said moldingstep including introducing said composition into a mold; and removingsaid molded composition from said mold, said composition containing saidinsect wax in amount effective to cause sufficient shrinkage of saidmolded article relative to said article without said insect wax toimprove the release properties of said composition from said mold. 18.The method of claim 17 wherein said composition comprises at least about1% by weight of insect wax.
 19. The method of claim 18 wherein saidinsect wax comprises beeswax.
 12. The method of claim 19 wherein saidcomposition comprises at least about 3 weight percent beeswax.
 21. Themethod of claim 17 wherein said vegetable-derived compound(s) comprisestearic acid.
 22. The method of claim 17 wherein said vegetable-derivedcompound(s) comprise ester of stearic acid.